Tamper evident hybrid resealable container

ABSTRACT

The present invention relates to a composite container comprising a bottom film layer and a top film layer at least partially adhered to the bottom film layer. The top film layer is scored to form at least one resealable flap and at least one pull tab which is not adhered to the bottom film layer. The bottom film layer comprises at least one cavity opening. A cardboard layer is adhered on its lower surface to the upper surface of the top film layer, wherein the cardboard layer has at least one cavity opening which is substantially aligned with the scoring of the top film layer resealable flap and the cardboard layer is perforated to define a perimeter of at least one pull tab which is substantially aligned with and adhered, on its underside, to the upper surface of the top film layer pull tab.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.16/386,688, filed Apr. 17, 2019 entitled “TAMPER EVIDENT HYBRIDRESEALABLE CONTAINER”, which is a continuation of U.S. patentapplication Ser. No. 15/656,481, filed Jul. 21, 2017, issued as U.S.Pat. No. 10,351,294, entitled “Tamper Evident Resealable Containers”,which is incorporated herein in its entirety.

FIELD OF THE INVENTION

The present invention relates generally to tamper evident resealablecontainers.

SUMMARY OF THE INVENTION

In an embodiment, the present invention relates to a composite containerwhich has a bottom film layer and a top film layer at least partiallyadhered on its lower surface to the upper surface of the bottom filmlayer. The top film layer is scored to form at least one resealable flapand at least one pull tab continuous with the resealable flap, whereinthe resealable flap is resealably adhered to the bottom film layer andthe pull tab is not adhered to the bottom film layer. The bottom filmlayer comprises at least one cavity opening. A cardboard layer isadhered on its lower surface to the upper surface of the top film layer,wherein the cardboard layer has at least one cavity opening which issubstantially aligned with the scoring of the top film layer resealableflap and the cardboard layer is perforated to form at least one pull tabwhich is substantially aligned with and adhered, on its underside, tothe upper surface of the top film layer pull tab.

According to an aspect, the present invention provides a resealablecontainer comprising a bottom film layer, a top film layer, and acardboard layer set forth in at least one wall of the container. The topfilm layer is partially adhered on its lower surface to the uppersurface of the bottom film layer via an adhesive layer which comprisesat least one resealable adhesive zone, at least one permanent adhesivezone, and at least one adhesive-free zone. The top film layer is scoredto form at least one resealable flap which is disposed partially withinthe at least one resealable adhesive zone and partially within the atleast one adhesive-free zone. The top film layer is also scored to format least one pull tab which is continuous with the resealable flap andis disposed within the at least one adhesive-free zone. The bottom filmlayer is scored to form at least one cavity opening, an edge of which isdisposed substantially between the at least one resealable adhesive zoneand the at least one adhesive-free zone. The cardboard layer ispermanently adhered on its lower surface to the upper surface of the topfilm layer and has at least one cavity opening which is substantiallyaligned with the scoring of the top film layer resealable flap. Thecardboard layer is additionally perforated to form at least one pull tabwhich is substantially aligned with and permanently adhered, on itsunderside, to the upper surface of the top film layer pull tab.

According to another aspect, the present invention also provides amethod for making a resealable container comprising providing a bottomfilm layer, a top film layer, and a cardboard layer. The method theninvolves laminating the upper surface of the bottom film layer to theunderside of the top film layer using a pressure sensitive adhesive anda permanent adhesive to form a laminated film, wherein the adhesives arepattern applied. The top film layer is then scored to form at least oneresealable flap which is continuous with at least one film pull tab. Thebottom film layer is then scored to form at least one film cavityopening. The cardboard layer is then cut to form at least one cardboardcavity opening. The cardboard layer is perforated to form at least onecardboard pull tab. The upper surface of the laminated film is adheredto the underside of the cardboard layer using a permanent adhesive,wherein the cardboard cavity opening is substantially aligned with theresealable flap scoring and the cardboard pull tab perforations aresubstantially aligned with the film pull tab scoring.

The accompanying drawings, which are incorporated in and constitute apart of this specification, illustrate one or more embodiments of theinvention and, together with the description, serve to explain theprinciples of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

A full and enabling disclosure of the present invention, including thebest mode thereof directed to one of ordinary skill in the art, is setforth in the specification, which makes reference to the appendeddrawings, in which:

FIG. 1 is a perspective view of an embodiment of a container of thepresent invention in a closed configuration;

FIG. 2 is a perspective view of an embodiment of a container of thepresent invention in an open configuration;

FIG. 3 is a perspective view of an embodiment of a container of thepresent invention in an open configuration;

FIG. 4 is an exploded view of a tab of a container of the presentinvention;

FIG. 5 is a cross sectional view of a tab of a container of the presentinvention;

FIG. 6A is a top view of an embodiment of the film of the presentinvention;

FIG. 6B is a top view of an embodiment of the top layer flexible film ofthe present invention;

FIG. 6C is a top view of an embodiment of the bottom layer rigid film ofthe present invention;

FIG. 6D is a top view of an embodiment of the cardboard layer of thepresent invention;

FIG. 6E is a perspective view of an embodiment of the multi-layerresealable container of the present invention; and

FIG. 7 is a cross sectional view of a tab portion of a container of thepresent invention.

FIG. 8 is a diagram illustrating an embodiment of a method of making thecontainers of the invention.

Repeat use of reference characters in the present specification anddrawings is intended to represent the same or analogous features orelements of the invention.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

Reference will now be made in detail to presently preferred embodimentsof the invention, one or more examples of which are illustrated in theaccompanying drawings. Each example is provided by way of explanation ofthe invention, not limitation of the invention. In fact, it will beapparent to those skilled in the art that modifications and variationscan be made in the present invention without departing from the scope orspirit thereof. For instance, features illustrated or described as partof one embodiment may be used on another embodiment to yield a stillfurther embodiment. Thus, it is intended that the present inventioncovers such modifications and variations as come within the scope of theappended claims and their equivalents.

A variety of food and non-food products are packaged using cardboard orpaperboard containers. Folded cardboard containers or cartons are wellknown in the art to be used for this purpose. These containers are oftenopened by manually separating layers of cardboard that are glued oradhered together at a closure. Once the adhesive seal is broken and, insome embodiments, other seams are perforated (for example, along thesidewall of the container), the container contents can be accessed.However, the typical container cannot be resealed in a manner thateffectively preserves the freshness of the container contents. Forexample, if a cardboard flap is merely fitted within a cardboard slot inorder to reclose a container, the unused products within the containermay be susceptible to being adversely affected by exposure to thesurrounding environment (e.g., becoming soggy, drying out, etc.).Accordingly, there is a desire to be able to reclose a cardboard foldedcontainer after its initial opening to keep the product that remains inthe package fresh. In addition, in an embodiment, such container alsocomprises tamper evidence features which allow a consumer to readilydetermine whether a container has already been opened.

In an embodiment, the present invention comprises a folded cardboard orpaperboard container which has a film window that allows consumers toaccess the contents of the container therethrough. The film window maybe clear, allowing the consumer to view the contents of the container.Such a window not only provides the consumer with the ability to comparethe appearance of competing products, but also provides the consumerwith confidence that the product does not have any defects, such as foodspoilage in the case of food products, prior to making a purchase.

In this embodiment, the container is opened via the film window, whichavoids any interference with the structural integrity of the cardboardcontainer. No perforation or separation of sidewalls, or the like, isnecessary. The container is additionally resealable via the film layer,allowing the consumer to open the container, remove the desired contentsfrom the container, and then reseal the film layer to the containerthrough the use of a pressure sensitive adhesive. The container can thusbe repeatedly opened and resealed. Finally, in some embodiments, thecontainer has a tamper evidence feature comprising the cardboard layer,which allows a consumer to more readily determine, by visual inspection,whether the container has been opened. Because the tamper evidencefeature is presented in the cardboard layer rather than the film layer,use of the tamper evidence feature of the container additionally avoidsotherwise common tearing issues within the film layer.

The container of the present invention can be used in connection withthe packaging of food and non-food products. In various examples, theinventive container may be used to store cookies, crackers, doughnuts,cakes, pies, or any other products which may be opened and resealed, andwould be susceptible to being adversely affected by exposure to thesurrounding environment.

The container of the present invention may comprise a reclosable foldingbox, container, or carton of sheet material having an interior and anexterior with at least one tamper evidence feature. The container may beproduced from any suitable material, including paperboard, cardboard, orthe like, cut and/or punched out as appropriate, and provided withappropriate folding lines, scoring lines, and/or predetermined breaklines. The container material may comprise any thickness known in theart. Though the container set forth in the drawings is illustrated as arectangular box, the container is not limited to any shape orconfiguration. The container of the invention may comprise any design,shape or configuration known in the art, including but not limited tosquare, rectangular, trapezoidal, or any other shape. Certain walls orfeatures of the container may be folded, scored, broken, and/or insertedor adhered together, as appropriate, in order to form the basiccontainer shape.

Turning to the drawings, FIG. 1 illustrates a perspective view of anembodiment of a container of the present invention. As set forth in FIG.1, in an embodiment, the container 100 comprises a body 116 which has atop wall 101, a front wall 102, a bottom wall 103, a back wall 104, andtwo side walls 105. The container walls (101, 102, 103, 104, and 105)define an interior portion of the container which is designed to holdthe contents of the container (i.e. doughnuts or cookies). The containeradditionally comprises an opening 106 which leads to the containercavity 115. In some embodiments, the container opening 106 is defined inonly the top wall 101 of the container. However, the container opening106 could alternatively be defined in one or more other container walls.For example, the container opening 106 could be defined in the top wall101 of the container, but may also extend partially into the front wall102 of the container. Similarly, the container opening 106 is shown inthe drawings as extending completely to the rear edge of the top wall101, but could end before the rear edge. The container opening 106 isshown as extending near, but not fully to the front edge of top wall101, but again, could extend fully to the front edge of top wall 101 orcould even extend partially into front wall 102.

The container 100 additionally comprises a film layer 108. The filmlayer 108 may comprise a multilayer flexible film. For example, the filmlayer 108 may comprise a top layer flexible film 109 and a bottom layerflexible film 110 (shown in FIG. 2). The film utilized herein maycomprise any flexible packaging film known in the art, including but notlimited to, polymer films, metalized polymer films, papers, metal foils,polyester films, polyolefin films, polyethylene terephthalate (PET)polypropylene (OPP), metalized polyester (MPET), any combinationthereof, or any other suitable film known in the art. In an embodiment,the film 108 may comprise a pre-printed film or label.

In certain embodiments, the film 108 of the invention may additionallycomprise a barrier layer, providing a barrier against the passage ofoxygen, other gases, and/or moisture. In some embodiments, the barriermay prevent wicking or leakage of a food product into and through thecontainer walls. In other embodiments, the film 108 may additionallycomprise one or more metallization layers or foil layers, which may behelpful in preventing a laser or die cutting machine from penetratingthrough the entire thickness of the top film 109 and/or the bottom film110.

In the embodiment wherein the film layer 108 comprises a two layer film,the bottom side of the top layer flexible film 109 and the top side ofthe bottom layer flexible film 110 may be permanently affixed, in someareas, and may be releasably affixed, in areas, through use ofappropriate adhesives. In locations wherein the film layers 109 and 110should be releasably affixed, the adhesive may comprise a pressuresensitive adhesive (“PSA”). Any suitable PSA known in the art may beutilized in the present invention. For example, the PSA may comprise anacrylic, a natural rubber, a synthetic rubber, a silicone, a butyl, oran ethylenevinylacetate (“EVA”). The PSA should be selected such that itreleasably secures the top film 109 to the bottom film 110. The PSAutilized should allow the top film 109 and the bottom film 110 to beseparated and resealed multiple times by the end user. Optionally, morethan one PSA may be utilized, wherein the PSAs allow the bonding of thetop film 109 to the bottom film 110 at different levels of affinity.

In locations wherein the film layers 109 and 110 should be permanentlyaffixed, the adhesive may comprise any permanent adhesive known in theart. The permanent adhesive should be selected such that it permanentlyadheres the top film 109 to the bottom film 110 (or any two relevantsurfaces), without damaging the relevant films/surfaces or the adhesive,particularly during the opening and reclosing of the container.Optionally, more than one permanent adhesive may be utilized, whereinthe permanent adhesives allow the bonding of the top film 109 to thebottom film 110 at different levels of affinity.

In an embodiment, the multi-ply film 108 of the invention may havepermanent adhesive zone and a PSA zone. For example, as shown in FIGS.6B and 6C, the bottom film 110 may have a permanent adhesive zone 601and a PSA zone 602. Similarly, the top film 109 may have a permanentadhesive zone 603 and a PSA zone 604. The bottom film 110 may be coated,on its top side, with a permanent adhesive in the permanent adhesivezone 601. Alternatively, or in addition to the adhesive layer applied tothe bottom film 110, the top film 109 may be coated, on its bottom side,with a permanent adhesive in the permanent adhesive zone 603. The topfilm 109 may also be coated, on its bottom side, with a PSA in the PSAzone 604. The top film 109 may be applied to the bottom film 110 suchthat the permanent adhesive zone 601 of the bottom film 110 is inregistry with the permanent adhesive zone 603 of the top film 109.Similarly, the PSA zone 602 of the bottom film 110 should be in registrywith the PSA zone 604 of the top film 109.

In addition, the top film 109 and the bottom film 110 may each containan adhesive-free zone 112 (see FIG. 6C). That is, when the top film 109is applied to the bottom film 110, there is no adhesive between the twolayers in the adhesive-free zone 112. The adhesive-free zone 112 may bedisposed in the location of a top film 109 pull tab 111. In anembodiment, the adhesives may be pattern applied to create theadhesive-free zone, wherein no adhesive is applied. In otherembodiments, the entire surface of one or more of the top film 109 orthe bottom film 110 may be coated with one or more adhesives and therelevant adhesives may be deadened to create the adhesive-free zone.

In an embodiment, the permanent adhesive and the PSA are applied to thetop film 109 and/or bottom film 110 in a pattern. In this embodiment,the adhesive free-zone 112 may be avoided or deadened after applicationof adhesive. In another embodiment, the top film 109 or bottom film 110may be flooded with PSA, optionally with the exception of theadhesive-free zone 112. Alternatively, the adhesive free-zone 112 may bedeadened after application of PSA. In this embodiment, the die cutpattern in the top film will allow the layers to separate at theresealable flap 114 without separating in zone 603. In this embodiment,no permanent adhesive is utilized. In another embodiment, the top film109 (bottom surface) or bottom film 110 (top surface) may be floodedwith permanent adhesive. After the permanent adhesive dries, zone 604may be coated with PSA. The adhesive free-zone 112 may be avoided ordeadened after application of the permanent adhesive. The layers maythen be sealed together.

The film pull tab 111 may be continuous with the top film 109. Moreparticularly, the pull tab 111 may be continuous with a resealable flap114 formed in the top film 109. The top film 109 may be scored at theovercut 606, optionally from top to bottom, to create a flap that coverscontainer opening 106 and cavity 115 in the container body 116. The pulltab 111 and the resealable flap 114 may be configured in any shape orsize known in the art. In an embodiment, the pull tab 111 may besemi-circular or semi-elliptical in shape.

In this embodiment, the end user can lift the pull tab 111, which may belocated in the adhesive-free zone 112. In an embodiment, the pull tab111 is not adhered to the container. In another embodiment, the pull tab111 is lightly adhered or releasably adhered to the container. In any ofthese embodiments, the end user may lift the pull tab 111, which therebyseparates and lifts the resealable flap 114 of the top film 109 awayfrom the PSA zone 602 of the bottom film 110. The user may then removeany desired contents from the container 100, and then press theresealable flap 114 back onto the PSA zone 602 of the bottom film 110 tore-adhere the flap 114 to the container, thereby resealing the container100. The container 100 can thus be repeatedly opened and resealed. In anembodiment, the PSA is present on the PSA zone 604 of the top film 109(bottom surface), but not on the PSA zone 602 of the bottom film 110(top surface).

In an embodiment, the resealable flap 114 may comprise a product viewingwindow 117, optionally located on the interior of the PSA zone 604. Theproduct viewing window 117 may be transparent, translucent, or opaque.The product viewing 117 area may comprise a label, printed graphics,logos, or the like, related to the products contained therein.Similarly, in an embodiment, the exterior of the cardboard layer 613 maycomprise a label, printed graphics, logos, or the like, related to theproducts contained therein. In a particular embodiment, any label,printing, or the like on the film 108 or resealable flap 114 may beblended or be continuous with a label, graphics, or other printinglocated on the exterior of the cardboard layer 613.

In an embodiment, the laminated film 108 is adhered within the interiorof the cardboard container. In this embodiment, the laminated film 108may receive an adhesive on the top side of the top film 109 within afront seal zone 608 and a rear seal zone 607. While front and rear sealzones are shown in the drawings, it should be understood that the film108 can be sealed within the container 100 in any area known in the art.In an embodiment, the film 108 may extend and be sealed along the fulllength of the front wall 102 and/or the rear wall 104. In anotherembodiment, the film 108 may completely cover the entire interior of thecontainer 100, and may provide improved barrier properties to thecontainer as a result.

In one embodiment, the front seal zone 608 may extend the length of thelaminated film 108 and/or the length of the top wall 101 or the frontwall 102 of the container 100. The front seal zone 608 may be locatedalong the top edge of the front wall 102 of the container or along thefront edge of the top wall 101 of the container. The rear seal zone 607may also extend the length of the laminated film 108 and/or the lengthof the top wall 101 or the front wall 102 of the container 100. The rearseal zone 607 may be located along the top edge of the rear wall 104 ofthe container or along the rear edge of the top wall 101 of thecontainer. Similarly, in an embodiment, the laminated film 108 may besealed to the container 100 at the top of the side walls 105 or thesides of the top wall 101. In any embodiment, the laminated film 108 maybe hermetically sealed within the container 100. In an embodiment, thelaminated film 108 is sealed within the interior of the container.

The hermetic seal described herein may be advantageous over designs thathave different entry points into the container. For example, in anembodiment wherein the entry point into the inventive container isthrough the flexible resealable window in the top wall, the front, back,and/or side walls are not involved in container entry. Thus, the frontand/or back walls, for example, can be sealed permanently to the topwall, with the laminated film in place. More aggressive adhesives can beused than would be available if the laminated film did not extend intothe front and/or back walls. This type of aggressive adhesive use maynot be available to use in a container that opens through the frontwall. Particular carton geometries that would be unavailable infront-entry containers, for example, may be used in the presentinvention. In addition, the resulting container may have an improvedbarrier to the environment due to the expanse of the laminated film.

Turning to FIG. 6D, in an embodiment, the container top wall 101contains a cardboard opening 609 defined by an edge 610. The cardboardopening 609 and edge 610 may be created by laser cutting or die cuttingthe cardboard material, or by any other method known in the art. In anembodiment, the edge 610 is similarly sized, shaped, and oriented tothat of the overcut 606 of the top film 109.

In an embodiment, the laminated film 108 shown in FIG. 6A is registeredwith the cardboard layer 613 shown in FIG. 6D. In an embodiment, theedge 610 is in registration with the overcut 606 of the top film 109.Thus, when the container is opened via the resealable flap 114, the PSAzone 602 of the bottom film 110 extends beyond the edge of the edge 610,into the interior of the opening 106. The PSA zones 602, 604 should besized such that the PSA zone 604 of the resealable flap 114 cancomfortably be replaced onto the PSA zone 602 of the bottom film 110 toreseal the package, but should not be so large as to impede access tothe contents of the container 100 through the opening 609. In anembodiment, the width of the PSA zones 602, 604 may be roughlyequivalent. In a particular embodiment, the width of the PSA zones 602,604 may be less than about 2 inches. In another embodiment, the width ofthe PSA zone 602, 604 may be less than about 1 inch. In still anotherembodiment, the width of the PSA zone 602, 604 may be approximately 1inch.

As noted above, the cardboard opening 609 may be disposed such that itextends near or to the rear edge 611 of the top wall 101. In a foldedcontainer, the rear edge 611 may comprise the fold of the box betweenthe top wall 101 and the rear wall 104. Similarly, the cardboard opening609 may be disposed such that it also (or alternatively) extends near orto the front edge 612 of the top wall 101. In a folded container, thefront edge 612 may comprise the fold of the box between the top wall 101and the front wall 102.

In an embodiment, a cardboard pull tab 113 is disposed adjacent thecardboard opening 609. The cardboard pull tab 113 may be disposedadjacent any edge or side of the cardboard opening 609. The cardboardpull tab 113, in an embodiment, has perforations 121 along at least someedges. In an embodiment, the cardboard pull tab 113 may be disposedalong a two-ply container wall, in which case it may be necessary tohave perforations along the pull tab 113 edge which is continuous withthe two-ply wall edge.

In an embodiment, the cardboard pull tab 113 and has a cut area 118along at least one edge. The cut area 118 (also referred to as an openarea or a separated area) may allow a user to slide a finger beneath thepull tab 113 and separate it from the container body 116. Alternatively,the cardboard pull tab 113 may have a small tab 301 (shown in FIG. 3)which is not affixed to the container wall and may be grasped to removethe pull tab 113 from the container wall to which it is perforatedlyconnected.

In an embodiment, the cardboard pull tab 113 is disposed in the frontwall 102 of the container. In another embodiment, the cardboard pull tab113 is disposed in the top wall 101 of the container. The cardboard pulltab 113 may be disposed in any wall or in any location within a wall.

In an embodiment, the cardboard pull tab 113 is adhered on itsunderside, via a permanent adhesive 401, to the top side of the filmpull tab 111 (see FIG. 4). It should be understood that the permanentadhesive 401 may be applied to either or both of the cardboard layer 613or the top film 109 during manufacture. In an embodiment, the entirecardboard layer 613 is permanently adhered, on its underside, to the topside of top film 109. In this embodiment, when the cardboard pull tab113 is separated from the cardboard layer 613 by a user, it remainsaffixed to the film pull tab 111. The combined pull tab (cardboard/film)can then be pulled upward and/or backward, which separates theresealable flap 114 from the remainder of the laminate film 108 at theovercut 606.

FIG. 7 illustrates a cross-sectional embodiment of the pull tab 111,113, top film 109, and bottom film 110. In this embodiment, thecardboard tab 113 is affixed to the film tab 111 via a permanentadhesive 401. The top film 109 is permanently affixed to the bottom film110 in sections and is resealably affixed to the bottom film 110 in thePSA zones 602, 604 via a PSA 701.

In an embodiment, the cardboard pull tab 113 comprises a tamper evidencefeature of the container. In this embodiment, the cardboard pull tab 113may be continuous with one or more walls of the container, but includesan area of weakness created, for example, by a scored, perforated, orthinned line, or by forming the pull tab 113 out of a highly orientedmaterial that has a tendency to split along a break line. Once thecardboard pull tab 113 is split or broken from the container body 116,it cannot be reaffixed to the container body 116. Once the cardboardpull tab 113 is split or broken from the container body 116 through theprocess of opening the container 100, in an embodiment, it may hang freeof the container body 116, remaining affixed to the container 100 dueonly to its permanent adherence to the film pull tab 111. The hangingcardboard pull tab 113 provides a clear visual indication that thecontainer 100 has already been opened.

In an embodiment, the container may comprise more than one cavity 115.In this embodiment, the cardboard layer 613 may define one or morecardboard openings 609. Additionally, in this embodiment, the containermay utilize an adhesive-free zone as is set forth in U.S. patentapplication Ser. No. 15/442,779, filed Feb. 27, 2017, which isincorporated herein by reference in its entirety.

As noted above, in an embodiment, the cardboard layer 613 may comprise alabel area 614, wherein company logos, photos, designs, and the like maybe displayed. In another embodiment, a separate film label may beapplied and permanently affixed to the outside of the cardboard layer613 in the label area 614. Alternatively, a separate film label may beapplied and permanently affixed to the outside of the cardboard layer613 prior to cutting edge 610 and creating the cardboard opening 609. Inthis embodiment, the edge 610 may extend through both the cardboardlayer 613 and any label layer.

Method of Making

The method of making the container blank can be generally described asfollows and will be more fully described below:

1. Laminate the top and bottom film layers together to form a laminate;

2. Undercut and overcut the film laminate;

3. Cut the cardboard layer to form the container opening and perforatethe cardboard pull tab; and

4. Adhere the film laminate to the underside of the cardboard layer.

Optionally steps 3 and 4, above, could be reversed.

Referring to FIG. 8, top film 109 and bottom film 110 may be provided insheet form. PSA 803 and a permanent adhesive 804 may be (simultaneouslyor sequentially) pattern applied to the bottom surface of the top film109 in predetermined areas. The adhesives may be applied in any suitablepatterns but, in an embodiment, leaves at least one adhesive-free zone112 at the location of the pull tab 111 and at least one adhesive-freezone in the location of the product viewing window 117. The adhesivesmay optionally be dried at a drying station such as an oven or the like.

Next, the top film 109 and bottom film 110 may be adhesively joined viathe adhesives to form a laminated film 108. This may be accomplishedusing a laminating machine comprising two rollers forming a niptherebetween, or may be accomplished using any other method known in theart. In an embodiment, the top film 109 and bottom film 110 should besubstantially coextensive with each other during the laminating process.For example, if the top film 109 and bottom film 110 are rectangular,the width and length of the top film 109 should match the width andlength of the bottom film 110. The laminated film 108 may be rectangularor any shape suitable for use with the desired container.

The laminated film 108 is then fed to a first scoring station 808 wherean undercut 605 may be scored in the bottom film 110. The undercut 605may be formed with a laser, with a die cutting machine or by anysuitable means and may extend through the entire thickness or almost theentire thickness of the bottom film 110. In an embodiment, the undercut605 is in registration with the inside border between the PSA zone 604pattern and the product viewing window 117 of the top film 109. Packageintegrity features may be cut into the bottom film 110 during this stepwell. In an embodiment, the undercut 605 may include a hinge such thatupon opening the label, the resealable flap 114 will hinge between thedie-cuts and remain adhered to the package. In an embodiment the hingemay be an undercut “j-hook” hinge 615 or an overcut back hinge, but itshould be understood that any mechanism which creates a stopping pointthat inhibits the complete removal of the flap 114 from the productpackage could be utilized.

The laminated film 108 may then be fed to a second scoring station 809where an overcut 606 is formed in the outer facing surface of the topfilm 109, through the location of the cardboard opening 609. The overcut606 is preferably formed substantially in registration with the outsideborder of the PSA zone 604 pattern, although it may overlap the PSAslightly. The overcut 606 may be formed with a laser, with a die cuttingmachine or by any suitable means and may extend through the entirethickness or almost the entire thickness of the top film 109.

It should be understood that the first and second scoring stations mayapply overcuts or undercuts, in any order, and that a single scoringstation could be utilized for both the undercut and overcut.

Cardboard layer 613 may also be provided in sheet form on a roller andmay be die-cut or laser cut 801 to form at least cardboard edge 610,cardboard opening 609, and optionally, the cut area 118 of cardboard tab113. The container wall shape(s) may also be cut such that the finalcardboard layer 613 comprises a container blank that can be folded orotherwise assembled into a container. Simultaneously, before, orafterward, the cardboard layer 613 may be scored or perforated 802 invarious regions around the cardboard tab 113, creating perforations 121that permit the cardboard tab 113 to be removable from the relevantcontainer wall(s). Again, the cutting and perforations made to thecardboard layer 613 may be accomplished in any order, at separatestations or at the same stations. The skeleton 806 of the cardboardlayer 613, containing the cardboard opening 609, may be removed anddiscarded.

Next, a permanent adhesive may be pattern applied 805 to the top surfaceof the top film 109 in predetermined areas. The permanent adhesiveshould be applied such that leaves at least one adhesive-free zone in alocation that will be registered with the cardboard opening 609 of thecardboard layer 613 once the cardboard layer 613 and the laminated film108 are adhered. Alternatively, a permanent adhesive may be appliedacross the entire bottom surface of the cardboard layer 613, whichalready has been cut and the cardboard opening 609 removed. Thepermanent adhesive may optionally be dried at a drying station such asan oven or the like.

Next, the laminated film 108 and cardboard layer 613 may be adhesivelyjoined via the permanent adhesive to form composite 807. This may beaccomplished using two rollers forming a nip therebetween, and/or may beaccomplished using any method known in the art, such as hot melt, heatseal, UV-activated seal, ultrasonic seal, energy-curable adhesive, orthe like. In an embodiment, the laminated film 108 and cardboard layer613 should be substantially coextensive with each other during theadhesion process. For example, if the laminated film 108 and cardboardlayer 613 are rectangular, the width and length of the laminated film108 should match the width and length of the cardboard layer 613. Thelaminated film 108 may be rectangular or any shape suitable for use withthe desired container. The laminated film 108 and cardboard layer 613should be registered such that the cardboard opening 609 of thecardboard layer 613, for example, is in registry with the outer edge ofthe PSA zone 604 of the top film 109. Similarly, the cardboard tab 113of the cardboard layer 613 should be in registry with the adhesive-freezone 112 (which is adhesive-free between top film 109 and bottom film110, but has a permanent adhesive between the top film 109 and thecardboard layer 613). Optionally, the composite material 807 may then beUV-cured or heat-sealed. The composite material may then be fed onto aroll for further use or the container blanks may be separated, stacked,and/or stored. Alternately, the container blanks may then be assembledinto containers.

Method of Use

The container 100 can be opened by separating the cardboard pull tab 113from the front wall 102 (or other wall of which it may be continuous) ofthe container 100. More particularly, in an embodiment, the user canslide a finger beneath the cut portion 118 of the pull tab 113, or graspthe 301 tab, and break the perforations 121 along the sides of the pulltab 113. The pull tab may then be separated from the relevant wall ofthe container 100 and may hang freely. In an embodiment, the film pulltab 111, which is permanently adhered to the underside of the cardboardpull tab 113, is not adhered to the container 100 and the cardboard/filmpull tab can be lifted away from the surface of the container 100. Whenlifted away from the surface of the container 100, FIGS. 2-3 illustratethe previous tab location 120. The previous tab location 120, in anembodiment, does not contain any adhesive, PSA or otherwise. Likewise,in an embodiment, the underside of the film pull tab 111 does notcontain any adhesive, PSA or otherwise. In this embodiment, the pull tab111, 113 hangs freely as soon as the cardboard pull tab 113 is separatedfrom the relevant container wall by breaking the perforations.

In a separate embodiment, the previous tab location 120 and/or theunderside of the film pull tab 111, contains PSA or another lightlyadhering adhesive. In this embodiment, the film pull tab 111 must belifted from the container wall to fully separate the cardboard/film pulltab from the container. In either embodiment, the separatedcardboard/film pull tab provides a tamper evidence indicator—the usercan visually see that the cardboard perforations are broken and,therefore, the container has been opened.

In use, as the user continues to pull, the resealable flap 114 releasesfrom the bottom film 110 due to the limited adhesion of the PSA. Morespecifically, the top film 109 will separate or break along the overcut606 as the pull tab 111, 113 is lifted, releasing the part of theresealable flap 114 which was adhered to the bottom film 110 via the PSA(i.e. the PSA zone 602, 604). This process opens at least one cavity 115in the container 110, due in part to the presence of the undercut 605,through which the contents can be accessed. The peeling back of theresealable flap 114 serves to create the cavity 115 by removing a partof the film layer 108 as the top film 109 is removed or peeled back.Thus, the undercut 605 defines a location of the cavity 115 of thecontainer 100 and is formed inwardly of the overcut 606 on theresealable flap 114. In FIGS. 2-3, the user has pulled back theresealable flap 114 to reveal the cavity 115 defined by the undercut605.

The user may then remove the container contents, as desired, and maythen reposition the resealable flap 114 back onto the bottom film 110.More particularly, the PSA zone 604 along the edge of the underside ofthe resealable flap 114 may be positioned directly on, and may sealcompletely to, the PSA area 602 on the upper surface of the bottom film110. As the resealable flap 114 is placed in position and, optionally,pressed downward, the film layers releasably seal to one another. Whenthe container 100 is reclosed via the resealable flap 114, in anembodiment, the pull tab 111, 113 remains unfixed and unsealed to thecontainer, as a tamper evidence indicator.

These and other modifications and variations to the present inventionmay be practiced by those of ordinary skill in the art, withoutdeparting from the spirit and scope of the present invention, which ismore particularly set forth in the appended claims. In addition, itshould be understood that aspects of the various embodiments may beinterchanged in whole or in part. Furthermore, those of ordinary skillin the art will appreciate that the foregoing description is by way ofexample only, and is not intended to limit the invention so furtherdescribed in such appended claims. Therefore, the spirit and scope ofthe appended claims should not be limited to the description of theversions contained therein.

What is claimed is:
 1. A method for manufacturing a resealable package,the method comprising: laminating a top film layer to a bottom filmlayer to form a multilayer film, wherein the film includes: a releasablyaffixed portion, in which the top film layer and the bottom film layermay be separated from and resealed to each other, and an unaffixedportion, in which the top film layer and the bottom film layer areseparate from each other; forming an overcut in the top film layer alongat least a portion of an outer periphery of the releasably affixedportion of the film to form a flap and a film pull tab, wherein the filmpull tab is disposed within the unaffixed portion; forming an undercutin the bottom film layer along at least a portion of an inner peripheryof the releasably affixed portion of the film; providing a fibrousmaterial layer shaped to form the resealable package with an interiorcavity when erected and including an opening which provides access tothe interior cavity of the resealable package when formed, wherein theopening matches the inner periphery of the releasably affixed portion ofthe film; perforating the fibrous material to form a fibrous pull tab;and adhering the fibrous material layer to the top film layer such thatthe opening is substantially aligned with the inner periphery of thereleasably affixed portion and the fibrous pull tab is substantiallyaligned with and adhered to the film pull tab.
 2. The method of claim 1,further comprising: erecting the resealable package to form the interiorcavity for storing items; and sealing the resealable package closed. 3.The method of claim 2, wherein sealing the resealable package compriseshermetically sealing the resealable package.
 4. The method of claim 3,wherein hermetically sealing the resealable package comprises lining theinterior cavity with the film.
 5. The method of claim 1, wherein thereleasably affixed portion of the film comprises pressure sensitiveadhesive applied between the top film layer and the bottom film layer.6. The method of claim 1, wherein the fibrous material layer comprisespaperboard.
 7. The method of claim 1, wherein the multilayer filmcomprises a barrier layer.
 8. The method of claim 1, wherein theunaffixed portion is formed by deadening adhesives applied between thetop film layer and the bottom film layer.
 9. The method of claim 1,wherein the fibrous pull tab comprises a tamper-evident feature.
 10. Themethod of claim 9, wherein the tamper-evident feature comprises aperforation feature formed in the fibrous material layer adjacent theopening, wherein the perforation feature is separable from the fibrousmaterial layer and adhered to the unaffixed portion of the film to forma pull tab.
 11. A resealable package, the package comprising: amultilayer film including: a top film layer laminated to a bottom filmlayer, a releasably affixed portion, in which the top film layer and thebottom film layer may be separated from and resealed to each other, anunaffixed portion, in which the top film layer and the bottom film layerare separate from each other, an overcut formed in the top film layeralong at least a portion of an outer periphery of the releasably affixedportion to form a flap and a film pull tab, wherein the film pull tab isdisposed within the unaffixed portion, and an undercut formed in thebottom film layer along at least a portion of an inner periphery of thereleasably affixed portion; and a fibrous material layer forming aninterior cavity for storing items, comprising an opening which providesaccess to the interior cavity, and comprising a perforated fibrous pulltab wherein: the opening is substantially aligned with the innerperiphery of the releasably affixed portion of the film, the fibrouspull tab is substantially aligned with the film pull tab, the fibrousmaterial layer is adhered to the top film layer, and the unaffixedportion of the film is disposed in the location of the film pull tab.12. The resealable package of claim 11, wherein the resealable packageis hermetically sealed.
 13. The resealable package of claim 11, whereinfilm covers the entire interior cavity of the fibrous material layer.14. The resealable package of claim 11, wherein the fibrous materiallayer comprises paperboard.
 15. The resealable package of claim 11,wherein the releasably affixed portion of the film comprises pressuresensitive adhesive applied between the top film layer and the bottomfilm layer.
 16. The resealable package of claim 11, wherein themultilayer film comprises a barrier layer.
 17. The resealable package ofclaim 11, wherein the unaffixed portion is formed by deadening adhesivesapplied between the top film layer and the bottom film layer.
 18. Theresealable package of claim 11, wherein the fibrous pull tab comprises atamper-evident feature.
 19. The resealable package of claim 11, whereinthe fibrous pull tab is disposed adjacent the opening in the fibrouslayer.
 20. The resealable package of claim 11, wherein the fibrousmaterial layer comprises the outermost layer of the package.